Manufacturing is a vast and challenging process that delves into every small step, from planning to execution. To overcome this challenge, manufacturing execution systems (MES) emerge as a viable option. This tool simplifies operations by keeping an eye on every process.
In this blog, we will delve into the world of MES and explore its core functions, evaluation, and trends in this field. It also highlights how companies are leveraging this tool for their success.
What are Manufacturing Execution Systems (MES)?
Manufacturing execution systems, or MES, are computerized systems used in manufacturing to track and record the transformation of raw materials into finished goods. MES provides detailed information on current conditions that help the manufacturer make decisions to improve production output. It is known as a functional layer between enterprise resource planning (ERP) systems and supervisory control and data acquisition (SCADA).
As this process is widely used on the plant floor for efficient and optimized production, its adoption is increasing rapidly. According to Extrapolate, the manufacturing execution systems (MES) market is expected to attain a revenue of $24.2 billion by 2030.
How do Manufacturing Execution Systems (MES) Work?
MES connects various stages of the manufacturing process, from planning to execution. It collects and analyzes real-time data from machines, sensors, and operators on the shop floor. This data is then used to monitor, control, and optimize production operations. MES systems provide features such as production scheduling, resource allocation, quality control, and inventory management. It enables better coordination, visibility, and decision-making by providing a centralized platform for managing and tracking manufacturing activities.
Evaluation of the Manufacturing Execution System (MES)
In 1997, the Manufacturing Enterprise Solutions Association (MESA) International represented 11 core functions. These functions aim to improve manufacturing operations management through effective IT applications. They serve as the foundation for the majority of plants.
Further, in 2004, the MESA model was updated as a collaborative MES, or C-MES, to include business operations. This model combines core operations with business operations to offer competition, outsourcing, and asset optimization features.
After this in 2008, the Strategic Initiatives Model was developed to connect enterprise-level strategic initiatives to plant operations, business operations, and production.
The current MESA model defines smart manufacturing and production by integrating existing concepts with advanced technology. It focuses on lifecycles, cross-lifecycle threads, enabling technologies, and evolving with emerging technologies.
11 Core Functions of Manufacturing Execution Systems (MES)
Below are the eleven core functions of MES that are considered a base for almost every manufacturing plant:
- Operations management
- Dispatching production units
- Product tracking and genealogy
- Data collection and acquisition
- Document control
- Quality management
- Maintenance management
- Process management
- Labor management
- Performance analysis
- Resource allocation and status
These core functions collectively enable MES systems to streamline and optimize manufacturing operations, improve efficiency, ensure quality, and enhance overall productivity.
How do MES and ERP Integration Bring Operational Clarity?
Integrating MES with Enterprise Resource Planning ERP offers operational clarity by ensuring that production planning is aligned with business processes. It allows businesses to orchestrate work orders and manage the availability of materials across the supply chain. MES and ERP integration offers real-time visibility into production schedules and changes on the shop floor. This streamlines factory-floor operations by managing and monitoring work-in-progress.
Additionally, this integration of MES and ERP allows companies to get a complete view of operations, enabling better decision-making and coordination across different departments. This integration facilitates corrective actions for defective products and helps eliminate the use of paper documents. Overall, MES and ERP integration bring operational clarity by offering a holistic and real-time view of operations and processes in the plant.
Trends in Manufacturing Execution Systems (MES)
Take a brief overview of the three trends in MES below:
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Cloud-Based MES Solutions
Cloud-based MES solutions are gaining popularity due to their flexibility, scalability, and cost-effectiveness. These solutions enable manufacturers to access MES functionalities from anywhere, facilitate collaboration, and support multi-site operations.
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Industrial Automation
The adoption of MES is growing due to the increasing implementation of industrial automation in both process and discrete industries. Automation enables real-time data collection, analysis, and control, leading to improved operational efficiency and productivity.
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Integration with Emerging Technologies
MES is integrating with emerging technologies like the Industrial Internet of Things (IIoT), big data analytics, and artificial intelligence (AI). This integration enables predictive maintenance, real-time monitoring, and data-driven decision-making, leading to improved efficiency and quality.
How do Manufacturing Execution Systems (MES) Make Operations Paper-Free?
MES solutions digitize and automate various processes that traditionally relied on paper-based documentation. It provides digital work instructions that can be accessed and viewed on devices such as tablets or computers. This eliminates the need for paper-based instructions, making them easily accessible to operators on the shop floor. It also offers centralized document management to store and manage all relevant documents digitally. Moreover, MES allows real-time updates for work instructions, ensuring employees have up-to-date information without relying on printed documents.
Several companies are adopting MES for its paper-free benefits and streamlined operations. For example, Pollington Machine & Tool, Inc., which faced challenges with updating and distributing instructions, adopted the MES developed by Pico MES. The transition from paper-based instructions to a MES solution eliminates paper binders, eliminates printing costs, and makes information more accessible. This shift also enabled machine shops to become more digital and paper-free.
In a Nutshell
Manufacturing execution systems (MES) play a crucial role in modern manufacturing operations. It provides real-time visibility, process control, and integration with other enterprise systems. MES helps improve operational efficiency, productivity, and quality. As manufacturing processes become more complex, MES enables operational clarity in the workforce. The evolving trends in MES drive the success of manufacturing organizations by streamlining workflows and making them digital and paper-free.
